Ship lap styled ship-slat components and manufacturing system

ABSTRACT

A ship lap styled wall covering system and apparatus is described. The apparatus includes panels which are disposed horizontally atop one another and are preferably joined via rabbet joints. The panels are configured to exhibit horizontal junction grooves when viewed from a front of the apparatus which facilitates the attachment of mounts such as brackets for the display of items and/or retail products on the wall covering. Similarly, vertical junction grooves may be present for the placement of similar mounts to vary the structure of the wall covering. Reinforced mounting notches disposed within the horizontal junction grooves are configured to conceal any and all screws used to affix the panels to the wall, and employ a rear portion substrate to ensure a structurally sound construct. Top and bottom molding panels may be installed to assist the aesthetic appeal of the system.

CONTINUITY

This application is a non-provisional application of provisional patent application No. 63/037,038, filed on Jun. 10, 2020, and priority is claimed thereto.

FIELD OF THE PRESENT INVENTION

The present invention relates to the construction and use of retail and residential wall coverings and/or display fixtures, and more specifically relates to a functional ship lap styled display system and manufacturing system thereof configured to facilitate an aesthetically appealing modern wall surface similar in appearance to that of conventional ship lap. The result apparatus enables the display of items on the wall of varying sizes and weights in an assortment of locations and positions.

BACKGROUND OF THE PRESENT INVENTION

Slatwall, which is sometimes referred to as slotwall, is a 4′×8′ panel/building material that is mounted in a vertical position. It has grooves machined into it horizontally so that hardware can be used to hang items from the vertical face. Slatwall was patented in 1966 by H. E. Graham of Claremont, Calif., U.S. Pat. No. 3,235,218 under the title Article Display Board. In the 1970's, slatwall grew in popularity and has continued to be a commonly used product globally in the retail and residential markets. Its consistent and ongoing use is due to the flexibility of displaying products and its capacity to organize an endless amount of items in various sizes and shapes. However, the design of slatwall has not evolved much since its inception.

Unfortunately, as the design and aesthetics of Slatwall has not changed, it leaves much to be desired in terms of customization, coloration, and utility. If there was a way by which a wall did not appear to be Slatwall when not being used for a product display or for organizational purposes, but was integrated with the versatility to allow for non-obvious slots to accept brackets to be utilized, more retailers and individuals would opt to use this type of wall covering rather than other alternatives. Such an apparatus could be positioned and manufactured to exhibit the appearance of authentic wood panels, with varied structure and appearance, in order to match the aesthetics of the retail space or residence accordingly.

Thus, there is a need for a wall mount system and apparatus which provides a non-obvious means by which items may be displayed on the wall. If walls were covered and finished with such an apparatus, picture frames could be hung using a bracket in a slot without having to drill or create nail holes in the walls that later have to be repaired. Similarly, with such a system, televisions could be hung and moved to new locations without having to repair walls. Shelves on shelf brackets and hang brackets can be moved to an infinite number of placements quickly without the use of tools to facilitate a customized and varied retail display space. Such a system preferably hides any and all screws to create the appearance of an aesthetically appealing and complete wall.

SUMMARY OF THE PRESENT INVENTION

This Summary of the Invention is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.

The present invention is a Ship-Slat wall system and process of manufacturing thereof, which is configured to securely create a stacked and random pattern on a wall for a non-conventional slatwall appearance but with functionality beyond existing decorative wall finishes, with a simple installation process due to the interlocking feature of the engineered and precisely machined planks. A wide variety of materials can be used to achieve the desired finished look of the wall or display but still maintain the slatwall functionality. Material thickness can range from ¾″ to any dimension. Heights of the planks can range from 2″ to any height. Length of planks can be cut in short lengths or in long continuous runs with vertical reveals where they butt together. It is envisioned that the substrate of the present invention is preferably composed of one or more of the following components: MDF, High pressure laminate thermofused laminate, cold fused laminate, plywood, melamine, vinyl, paint, wood, veneer, stain, color core material, composite, plastic, PVC, Acrylic, or metal.

The following brief and detailed descriptions of the drawings are provided to explain possible embodiments of the present invention but are not provided to limit the scope of the present invention as expressed herein this summary section.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate the present invention and, together with the description, further serve to explain the principles of the invention and to enable a person skilled in the pertinent art to make and use the invention.

The present invention will be better understood with reference to the appended drawing sheets, wherein:

FIG. 1A depicts a view of the preferred embodiment of the apparatus of the present invention as seen from the front.

FIG. 1B depicts a view of the side of the entire apparatus of the present invention.

FIG. 2 exhibits a side view of the raw substrate of the apparatus of the present invention.

FIG. 3 depicts an environmental view of the preferred embodiment of the apparatus of the present invention showing the functionality of the integrated and unapparent slots for hardware attachment.

FIG. 4 shows a view of the front and side of the panels of the present invention, depicting a cross-sectional view of the front portion and rear portions of each two-piece panel.

FIG. 5 exhibits a flow chart detailing the manufacturing process and construction process of the apparatus of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present specification discloses one or more embodiments that incorporate the features of the invention. The disclosed embodiment(s) merely exemplify the invention. The scope of the invention is not limited to the disclosed embodiment(s).

References in the specification to “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment, Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

The present invention is a modular wall-mount system and apparatus configured to act as a function, aesthetically pleasing wall covering configured to facilitate the attachment of items for display via conventional mounts. As such, the present invention is a wall covering (10) which comprises a series of panels (20) as shown in FIG. 1A which are deliberately segmented, and which are joined in a ship lap style to enhance the appearance and utility of the wall. These panels (20), also referenced as planks, preferably vary in width and length to lend to a more authentic replication of a wood paneled wall.

The panels (20) of the wall covering (10) consist of a front portion (105) and a rear portion (110) as shown in FIG. 4. The front portion (105) is shown to the observer when the wall covering (10) is constructed and installed, and the rear portion (110) functions as a substrate of the wall covering (10), providing stability and structural integrity to facilitate the mounting of heavy objects to the wall covering (10) via mounts. As such, the present invention is equipped with horizontal junction grooves (40) and vertical junction grooves (60) for the placement of the mounts. Mounts include conventional metallic hardware known in the industry to be used on conventional slatwalls, but may also include shelves (30), platforms, brackets, hooks, and other hardware configured to facilitate the display of objects including retail products.

Both a top and a bottom of the wall covering (10) apparatus is preferably equipped with molding panels (50) as shown in FIG. 1 to enhance the appearance of the present invention. The molding panels (50), as trim for the wall covering (10), are optional and need not be installed if not needed or desired.

The panels (20) of the present invention are preferably configured to interlock together via a rabbet joint which creates space vertically between panels (20) to mimic unoccupied space that appears horizontally when the horizontal junction groove (40) is not in use for the positioning of a shelf (30) or similarly mounted object. The rabbet joints of each panel junction preferably include a top portion (70) positioned at a top of each panel (20), and a bottom portion (80) disposed a bottom of each panel (20). The panels (20) interlock bottom-to-top and side-to-side as shown in FIG. 2.

Screws are preferably installed once a panel (20) has been placed atop a first panel (20), as the wall covering (10) is constructed from the bottom to the top. To remain obscured, the screws are placed at or near the screw position (100) as shown in FIG. 2, such that the screw is hidden behind a reinforced mount notch (95). The reinforced mount notch (95) is configured to provide the strength to a mount, such as a shelf (30) when installed, as it comes into direct contact with the hardware (such as brackets) of the mount per convention. A top rabbet notch (85) is configured to interlock with the bottom portion (80) of each panel as shown, ensuring the panels remain firmly together once erected.

The process of installation of the system and apparatus of the present invention, as shown in FIG. 5, is preferably as follows:

-   -   1. First, screw a starter strip onto the base of the wall or         display, securely. (120)     -   2. Next, place a panel (starting on the left side or the right         side of the opening) on top of the starter strip so that it         fully seats onto the top of the starter strip below. (130)     -   3. Place screws every 16″ or less along the top edge of the         panel to secure the row into metal studs or appropriate         structural wall material. (140)     -   4. Continue installing panels according to steps 2-3 down the         remaining length of the starter strip until the row is         completed. (150)     -   5. Next, cut the final panel in the row until it fits into the         remaining space. (160)     -   6. Then, seat the panel and screw it into position. (170)     -   7. Next, select the desired panel height for the next row and         cut the left side of the panel (if on the left side of the run)         so the vertical seams are offset from those of the row below for         the desired visual effect. (180)     -   8. Repeat steps 2-5 until the wall is completely covered. (190)     -   9. Attach base trim, top trim, and end caps as desired to         complete the install. (200)

In some embodiments of the present invention, the front portion (105) of the wall covering (10) may be equipped with texturization, patterns, embossing, brick fascia, or similar aesthetic element to coordinate with that of the space in which the present invention is disposed. As such, the front portion (105) may be one or more of a variety of colors, and accordingly, the panels (20) may be sized and shaped differently in accordance with the needs of the installation.

It should be noted that the front portion (105) and/or rear portion (110) of the present invention may be made from a variety of materials, including, but not limited to: MDF, High pressure laminate thermofused laminate, cold fused laminate, plywood, melamine, vinyl, paint, wood, veneer, stain, color core material, composite, plastic, PVC, Acrylic, or metal. Metal or acrylic inserts may be positioned within the horizontal junction grooves (40) to further enhance the payload capacity of the reinforced mounting notch (95) of each panel (20) segment.

It should be understood that the size and shape of the interlocking features are critical for ease of installation of the present invention, and provide the necessary tolerances for the components to fit together during installation. When the panels (20) are stacked on top of one another so the tab on the top of panels (20) is seated with the rabbet on the bottom of the panel (20) above it, the groove for the hardware spacing is consistently maintained at the proper opening size for mounting brackets to engage and cam into place securely. It should be noted that no glue or similar adhesive is required to complete the assembly of the apparatus.

Having illustrated the present invention, it should be understood that various adjustments and versions might be implemented without venturing away from the essence of the present invention. Further, it should be understood that the present invention is not solely limited to the invention as described in the embodiments above, but further comprises any and all embodiments within the scope of this application.

The foregoing descriptions of specific embodiments of the present invention have been presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the present invention to the precise forms disclosed, and obviously many modifications and variations are possible in light of the above teaching. The exemplary embodiment was chosen and described in order to best explain the principles of the present invention and its practical application, to thereby enable others skilled in the art to best utilize the present invention and various embodiments with various modifications as are suited to the particular use contemplated. 

I claim:
 1. An ship-lap styled interlocking vertical panel system for the display of retail items on a wall comprising: panels, said panels having a front portion, a rear portion, and four edges; wherein said four edges include two horizontal edges and two vertical edges; wherein said rear portion functions as a substrate of said panels; rabbet joints, said rabbet joints disposed on said two horizontal edges; wherein said rabbet joints are configured to interlock said panels together in series such that panels are disposed bottom-to-top and side-to-side; horizontal junction grooves, said horizontal junction grooves disposed horizontally between said panels; vertical junction grooves, said vertical junction grooves disposed vertically between said panels; wherein said horizontal junction grooves are configured to securely hold mounts; and wherein said mounts facilitate the placement of the retail items on the wall.
 2. The system of claim 1, further comprising: screws, said screws disposed in screw positions; wherein said screw positions are disposed on said horizontal edges of each panel; and wherein said screws are obscured by subsequently placed interlocking panels upon contact.
 3. The system of claim 1, wherein said mounts include metallic hardware selected from the following group: shelves, platforms, brackets, hooks, and eyelets.
 4. The system of claim 1, further comprising: molding panels, said molding panels disposed at a top and a bottom of the wall to serve as trim for the wall.
 5. The system of claim 1, wherein said substrate is composed of at least one material selected from the following group: MDF, High pressure laminate thermofused laminate, cold fused laminate, plywood, melamine, vinyl, paint, wood, veneer, stain, color core material, composite, plastic, PVC, Acrylic, or metal.
 6. The system of claim 1, further comprising: reinforced mount notches, said reinforced mount notches disposed horizontally on said bottom portions of said panels; and wherein said reinforced mount notches provide a leverage point for the positioning of said mounts.
 7. The system of claim 1, wherein said front portion of said panels is equipped with texturization, patterns, embossing, brick fascia, or similar aesthetic elements to coordinate the appearance of the panels with that of the space in which the panels are disposed.
 8. The system of claim 2, wherein said mounts include metallic hardware selected from the following group: shelves, platforms, brackets, hooks, eyelets.
 9. The system of claim 2, further comprising: molding panels, said molding panels disposed at a top and a bottom of the wall to serve as trim for the wall.
 10. The system of claim 2, wherein said substrate is composed of at least one material selected from the following group: MDF, High pressure laminate thermofused laminate, cold fused laminate, plywood, melamine, vinyl, paint, wood, veneer, stain, color core material, composite, plastic, PVC, Acrylic, or metal.
 11. The system of claim 2, reinforced mount notches, said reinforced mount notches disposed horizontally on said bottom portions of said panels; and wherein said reinforced mount notches provide a leverage point for the positioning of said mounts.
 12. The system of claim 6, further comprising: screws, said screws disposed in screw positions; wherein said screw positions are disposed on said horizontal edges of each panel; and wherein said screws are obscured by subsequently placed interlocking panels upon contact.
 13. A wall mount system which provides a non-obvious means by which items may be displayed on a wall comprising: panels, said panels having a front portion, a rear portion, and four edges; wherein said four edges include two horizontal edges and two vertical edges; wherein said rear portion functions as a substrate of said panels; rabbet joints, said rabbet joints disposed on said two horizontal edges; wherein said rabbet joints are configured to interlock said panels together in series such that panels are disposed bottom-to-top and side-to-side; horizontal junction grooves, said horizontal junction grooves disposed horizontally between said panels; vertical junction grooves, said vertical junction grooves disposed vertically between said panels; wherein said horizontal junction grooves are configured to securely hold mounts; wherein said mounts facilitate the placement of the retail items on the wall; screws, said screws disposed in screw positions; wherein said screw positions are disposed on said horizontal edges of each panel; wherein said screws are obscured by subsequently placed interlocking panels upon contact; wherein said mounts include metallic hardware selected from the following group: shelves, platforms, brackets, hooks, and eyelets; reinforced mount notches, said reinforced mount notches disposed horizontally on said bottom portions of said panels; and wherein said reinforced mount notches provide a leverage point for the positioning of said mounts.
 14. A method for installing a shiplap-styled ship-slat wall system for the display of items on a wall comprising: screwing a starter strip onto a base of the wall; placing a panel on top of the starter strip so that a bottom of the panel firmly seats within a rabbet joint of a top of the starter strip; placing screws every 16″ along a top edge of the panel, securing the panel into structural wall material of the wall; placing subsequent panels, bottom-to-top, together along the entirety of the top of the starter strip, completing one row once the subsequent panels approach ends of the starter strip; selecting a desired panel height for a next row from a selection of available panels; cutting the panels so that vertical seams disposed between placed panels are offset from those of the previous row below to achieve a shiplap appearance; interlocking subsequent panels to complete subsequent rows from the bottom to the top of the wall until the wall is completely covered with panels; screwing the panels into place via screws positioned in screw positions, the screw positions obscured by subsequently placed panels atop the screws; attaching a base trim to a bottom of the wall; attaching a top trim to a top of the wall; and attaching end caps to sides of the panels to complete the installation. 